Electronically controlled vehicle suspension system and method of manufacture

ABSTRACT

An air suspension system, comprising a manifold, defining a first and second port, each port defining a receiving region at the second end, wherein the first and second ports are arranged in a common plane, a channel intersecting the first and second port, a cavity intersecting each port, and a pressure sensor port, positioned between the first and second port, defining a sensor insertion axis normal to the common plane, the pressure sensor port separated from the first port, the second port, and the channel by a thickness; a first and second solenoid valve, each solenoid valve arranged within the cavity and coaxially arranged with the first and second ports, each solenoid valve comprising a connector; a pressure sensor arranged within the pressure sensor port, the pressure sensor comprising a connector; and an electronics module arranged parallel the common plane, the electronics module configured to electrically couple to the connectors.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/289,371 filed 28 Feb. 2019, which is a continuation of U.S.application Ser. No. 15/712,995 filed 22 Sep. 2017, which is acontinuation of U.S. application Ser. No. 14/971,520, filed 16 Dec.2015, which claims the benefit of U.S. Provisional Application Ser. No.62/092,723 filed 16 Dec. 2014, U.S. Provisional Application Ser. No.62/119,740 filed 23 Feb. 2015, and. U.S. Provisional Application Ser.No. 62/195,083 filed 21 Jul. 2015, each of which is incorporated in itsentirety herein by this reference.

TECHNICAL FIELD

This invention relates generally to the vehicle suspension field, andmore specifically to a new and useful electronically controlled airsuspension system and method of manufacture.

BACKGROUND

Vehicle suspension systems relying on air springs instead ofconventional steel springs can provide improved and adjustable ridequality. Historically, vehicles have incorporated air springs whereactive adjustments of suspension parameters (e.g., attenuation force,ride height, spring constants, etc.) are desired. Electronic controlsystems and software have recently been developed to provide automationand control (e.g., closed-loop control, open-loop control) to active airsuspension systems; however, such systems and methods suffer from anumber of drawbacks. In particular, many systems are excessively complex(e.g., systems that require numerous machining operations to form andassemble, need complicated arrangements of gaskets and seals to functionproperly, etc.), highly specified (e.g., systems that are made for aspecific vehicle configuration and/or lack reconfigurability), andexpensive to manufacture (e.g., systems of predominantly metalconstruction that are expensively machined, systems with high. partcounts that are intensively assembled, etc.). Other limitations ofconventional electronically controlled air suspension systems includeone or more of: unacceptable quality tradeoff with cost, lack ofmanufacturability for low cost, large system cross-section and/orfootprint causing difficulty with integration into other systems and/orfacilities, and other deficiencies.

Furthermore, construction of robust electronic control units, includingcomplex manifolds, that can be manufactured at a low per-unit cost isparticularly challenging. Challenges include: integration of sub-systemcomponents (e.g., actuators, electronic control systems, etc.) with themanifold; fabrication of the manifold; retooling of the electroniccontrol unit for various customer applications without undulyspecializing the assembly process; and reducing the number of operationsnecessary to electronically couple the internal components of theelectronic control units.

There is thus a need in the air suspension field to create a new anduseful electronically controlled air suspension system and method ofmanufacture. This invention provides such a new and useful system andmethod.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts a schematic of a first embodiment of the system.

FIG. 2A depicts a schematic representation of a functional relationshipbetween the system components of a second embodiment of the system.

FIG. 2B depicts a schematic representation of a functional relationshipbetween the system components of a third embodiment of the system.

FIG. 3 depicts an exploded view of a fourth embodiment of the system

FIG. 4 depicts a cutaway view of a first embodiment of the manifold.

FIG. 5 depicts a perspective view of the first embodiment of themanifold.

FIG. 6A depicts a perspective view of a variation of the pressure sensorport of the first embodiment of the manifold.

FIG. 6B depicts a top-down view of a variation of the pressure sensorport of the first embodiment of the manifold.

FIG. 7 depicts a specific example of an embodiment of the systemincluding a strut and a magnet.

FIG. 8 depicts a cross-sectional view through the manifold of a fifthembodiment of the system, including actuators and a filter.

FIG. 9 depicts an example flow pathway of a fluid particle through thefifth embodiment of the system.

FIG. 10 depicts a cross sectional view through the cover, electronicsmodule, and manifold of an example embodiment of the system.

FIG. 11 depicts a cross sectional view through the cover, electronicsmodule, manifold, and second stage manifold of an example embodiment ofthe system.

FIG. 12 depicts a perspective view of a variation of the manifold of asixth example embodiment of the system.

FIG. 13 depicts a perspective view of the manifold of the sixth exampleembodiment of the system, including actuators coupled to the second endsof the ports.

FIG. 14 depicts a perspective view of a cross section of the cover of anembodiment of the system, including a PCB assembly and a pressure sensoran assembled embodiment of the system.

FIG. 15 depicts a partially exploded cross sectional view through thecover, electronics module, and manifold of an embodiment of the system,including a pressure sensor and an actuator.

FIG. 16 depicts a perspective view of an embodiment of the system,including fittings emplaced in the ports and the input of the filter.

FIG. 17 depicts a perspective view of a cross section through the cover,electronics module, manifold, and actuator of an embodiment of thesystem configured to couple to a second stage manifold.

FIG. 18 depicts a partially exploded view of a seventh exampleembodiment of the system, including a dividing plane between themanifold and the cover that is perpendicular to the plane in which theactuators are oriented.

FIG. 19 depicts a block diagram of an example embodiment of a method. ofmanufacture of the system.

FIG. 20 depicts a schematic of an example embodiment of the system.

FIG. 21 depicts a perspective view of the manifold of an eighthembodiment of the system, including pressure sensor supports integratedwith the pressure sensor ports.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments of the inventionis not intended to limit the invention to these preferred embodiments,but rather to enable any person skilled in the art to make and use thisinvention.

As shown in FIG. 1, an embodiment of an electronically controlled airsuspension system 100 includes: a manifold 110, including a port 111,pressure sensor port 113, a channel 114, and a cavity 115; an actuator120; a pressure sensor 130 arranged in the pressure sensor port 113, thepressure sensor 130 including a connector 132; an electronics module140, including an electronics substrate 142, the electronics substrate142 arranged to enclose the actuator 120 and pressure sensor 130 withinthe manifold 110; and a cover 150, coupled to the manifold 110 andcooperatively enclosing the actuator 120, the pressure sensor 130, andthe electronics module 140. As described in more detail below, one ormore variations of the system 100 can omit one or more of the aboveelements, as well as provide a plurality of one or more of the aboveelements, in providing a suitable electronically controlled airsuspension system 100.

The system 100 functions to control air flow to and from services byelectronically controlling one or more actuators 120 to directpressurized air through a manifold 110, The system 100 can also functionas a command module for the control of one or more movable Obstructions172 of a second stage manifold 170. Examples of services to and fromwhich air flow can be controlled include: a set of air springs 182,active or semi-active dampers 184, an air compressor, a reservoir ofcompressed air, a hose, a second stage manifold 170, or any othersuitable system, subsystem, or component requiring a controllable sourceor sink of compressed air. Example configurations of the system 100alongside various services and external systems 180 are shown in FIGS.2A and 2B. The system 100 can be used in: a central tire inflationsystem, air control system for recreational vehicle systems (e.g.,slideouts, central locking, jacking systems, door opening and/or closingsystems), active braking systems (e.g., pneumatic braking, hydraulicbraking), vehicle stability control systems, medical devices (e.g.,alternating-pressure mattresses, seatpads for wheelchairs,blood-circulation enhancers), or in any other suitable application. Invariations, the system 100 can include one or more of the servicesdescribed above. The system 100 can additionally or alternativelyfunction to maintain a particular pressure value, set of pressurevalues, or range of pressure values in one or more of the servicesdescribed above. The system 100 can additionally or alternativelyfunction to provide a variable set of internal control and actuationcomponents based upon the specific needs of a user or service utilizingthe system 100.

As such, the system 100 can be configured for one or more of thefollowing: providing a flexible and/or reconfigurable arrangement ofinternal components that can be populated in the system according tocustomer/user needs; mounting to any suitable vehicle employing an airsuspension system; providing a common plane through which theconnector(s) 126, connector(s) 132, and/or external connector(s) 149perpendicularly pass to enable single-operation coupling of the pressuresensor(s) 130 and the actuator(s) 120 to the electronics module 140;arranging the actuator(s) 120 coaxially with the port(s) 111 to enable alarger electronics substrate 142 to be used, a decreased package size ofthe system 100, an injection-moldable cross section of the manifold 110,and decreased cost and complexity of the system 100; and selectivelyremoving material between the pressure sensor port(s) 113 and theport(s) 111 and/or the channel 114 to provide access between variousstatic pressures of portions of the system 100 and the pressuresensor(s) 130. In one variation, all the pins (e.g., connectors) of thevarious components (e.g., external connector 149, actuator 120, pressuresensor 130) extend in a common direction from their respective positionswithin the manifold 110 towards a common plane. The architecture of thisvariation enables PCB-to-connector coupling and PCB-to-manifold couplingin a single assembly step. The architecture additionally enablessingle-pass soldering of the connectors to the PCB. A single solderingstep can reduce stress on the printed circuit board (e.g., stressresulting from uneven thermal loading, mechanical loading, etc.) andlead to longer product lifetime and enhanced robustness. The system 100can also function to be conveniently and easily manufactured and/orretooled.

In variations, the system 100 is configured to maximize the number ofinjection-moldable parts of the system 100, including the manifold 110,which is preferably of unitary molded construction. However, the systemcan be otherwise manufactured.

Applications and Specific Examples

As noted above and as shown in FIG. 7, the system 100 can be integratedwith or include a suspension system of a vehicle 400. This can include anumber of external systems 180, including one or more air springs 182,active or semi-active dampers 184, vehicle mounting mechanisms 186, andexhaust ports 189. However, the suspension system can include any othersuitable component. The suspension system can be an air suspensionsystem, or be any other suitable suspension system. An air spring 182can be a bag, cylinder, bellows, or similar structure that can expand(lengthen, stiffen, harden) or contract (shorten, soften, flex) when airis either pumped in or removed, respectively. However, the air springcan be a piston or have any other suitable configuration. An air spring182 can function to provide a smooth and consistent ride quality to avehicle 400, or in some applications (e.g., a sport suspension) providedynamic, wide range-of-motion articulation to some vehicle suspension.An air spring 182 can also function as a service requiring a source ofcompressed air, to be provided by the system 100. An air spring 182 canalso function as a source of compressed air that must be exhausted toatmospheric pressure, which can be controlled and directed by the system100.

The system 100 can simultaneously control one or more air springs 182,When the system 100 controls multiple air springs 182, the system 100can individually control each air spring 182, control a first set of airsprings 182 based on the operation. parameters of a second set of airsprings 182, or otherwise control air spring operation. In a firstvariation, the system 100 can fluidly isolate the air springs 182connected to the system from each other (e.g., fluidly isolate a firstair spring from a second air spring). In a second variation, two airsprings 182 can be connected together through the system 100, causingpressure to equalize between the two air springs 182, providing anefficient means of suspension control for extremely uneven or irregularterrain, However, the system 100 can selectively or otherwise form anyother suitable fluid configuration between the air springs 182. Anactive or semi-active damper 184 is typically of similar mechanicalconstruction as an air spring, but with the preferred function ofdampening vibration that can be experienced by a vehicle 400 duringnormal operation (e.g., driving on a paved surface). However, the activeor semi-active damper can be constructed, connected to the system 100,or operated in any other suitable manner.

A vehicle mounting mechanism 186 functions to affix the system 100 to avehicle 400. A vehicle mounting mechanism 186 can include one or morebrackets, bolts, fasteners, straps, clips, or similar devices thatcouple the system 100 to the vehicle 400. The vehicle mounting mechanism186 can additionally or alternatively include a set of mating surfaces,some of which are constituted by portions of the system 100 (e.g., athrough-hole in the manifold 110) and some of which are defined byportions of the vehicle 400 (e.g., a bracket with a mating through-hole,to which the system 100 can be bolted, attached to a strut support ofthe vehicle 400). As a further alternative, the vehicle mountingmechanism 186 can include a receiving manifold to direct airflow toand/or from the system 100, into which the system 100 is inserted and towhich each of the ports 111 of the manifold 110 is connected. Thereceiving manifold preferably includes one or more tubes that are eachcoupleable to a corresponding port 111 of the manifold 110, each of theone or more tubes fluidly connected to a service requiring pressurizedair. Alternatively, the receiving manifold can define any suitabledirected flow pattern. Alternatively, the vehicle mounting mechanism 186can be any suitable mounting mechanism.

In a first specific example, the system 100 provides two controllablepressure lines, although the manifold 110 and electronics module 140 areconfigured to provide up to three controllable pressure lines inalternative configurations. The example system can include three ports111 and two actuators 120. The first actuator 120 is emplaced in (e.g.,arranged within) the cavity 115 of the manifold 110 and coaxiallyaligned with the first port 111, and the second actuator 120 is likewiseemplaced and coaxially aligned with the adjacent second port 111. Thethird port 111 can remain unused, and can remain open to the cavity 115or be sealed by a cap or other sealing mechanism. The system canadditionally include two pressure sensor ports 113, each located betweentwo adjacent ports 111 of the three ports 111 (e.g., the first pressuresensor port 113 between the first and second ports 111, the secondpressure sensor port 113 between the second and third ports 111). Thesystem can include a single pressure sensor 130, arranged within thefirst pressure sensor port 113 (e.g., the pressure sensor port 113positioned between the two ports 111 with corresponding actuators 120).

In a second specific example, the system 100 can be substantiallysimilar to the first specific example, and additionally include a firstair spring connected to the first port a second air spring connected tothe second port 111, and an exhaust connected to the third port 111. Assuch, the first air spring, the second air spring, and the exhaust are“services” connected to the system 100. The system can additionallyinclude a source of compressed air connected to an input of the system100. The actuators 120 are configured to selectively fluidly connect anddisconnect the services to one another and/or to the source ofcompressed air, with all airflow occurring within the manifold 110. In afirst configuration, the first air spring can be fluidly connected tothe second air spring, resulting in pressure equalization between thefirst and second air springs. In a second configuration, the first airspring can be fluidly connected to the source of compressed air, causingthe first air spring to expand as its internal pressure is increased. Ina third configuration, the first and/or second air spring can be fluidlyconnected to the exhaust, causing the first and/or second air spring tocontract as its internal pressure is reduced. The first air spring, thesecond air spring, and the exhaust can alternatively be variouslyconnected to and disconnected from one another, as well as to and fromother connected. external services and systems, in any other suitablemanner.

As shown in FIG. 9, an example flow path through an example embodimentof the system 100 includes an air particle flowing from an aircompressor through an input 161 of a filter 160. The air particle thenstrikes the filter plate 162, and is divested of dust particles in theair particle before passing into the expansion chamber 163. Uponexpansion, water vapor in the air particle condenses into a droplet,which adheres to the side wall of the expansion chamber 163 and collectsin a separate portion of the expansion chamber 163. The air particleturbulently flows through the expansion. chamber 163 and into the filterelement 164, and follows a tortuous path through the filter elementwhere it is divested of as much remaining water vapor as possible. Theair particle then enters the channel 114, and then into a first port 111with a corresponding first actuator 120 that is in an open position(i.e., in a position that fluidly connects the channel 114 and the port111). The air particle then travels through a compressed air lineconnected to the port 111, and then to an air spring 182 that isconnected to the compressed air line, raising the internal pressure ofthe air spring 182. A second actuator 120 is then actuated from a closedposition (i.e., a position that prohibits fluid communication betweenthe channel 114 and a port 111 corresponding to the actuator 120) intothe open position, and the air particle flows from the air spring 182,through the compressed air line, into the first port 111 and then thechannel 114 before entering the second port 111 (corresponding to thesecond actuator 120) and subsequently a second air spring 182. However,any suitable fluid (e.g., air, other gasses, Newtonian fluids,non-Newtonian fluids, etc.) can flow from a fluid source (e.g., theambient environment, reservoir, etc.) through the system along any othersuitable fluid path.

System

As noted above and as shown in FIGS. 1,3, and 4, an embodiment of thesystem 100 includes: a manifold 110, defining: a first and second port111; a channel 114; a cavity 115; and a pressure sensor port 113. Thesystem 100 can additionally include an actuator 120, a pressure sensor130 arranged within the pressure sensor port 113, an electronics module140, an integrated filter 160, a second stage manifold 170, and/or anyother suitable component. The system 100 is preferably assembled into aself-contained unit, as shown by example in FIG. 16, but canalternatively be configured in any other suitable manner.

2.1 Manifold

As shown in FIG. 4, the manifold 110 preferably defines a port 111, apressure sensor port 113, a channel 114, and a cavity 115. The manifold110 functions to direct fluid flow between one or more inputs and one ormore outputs, preferably in cooperation with the actuator(s) 120, butalternatively independently or with any other suitable component. Themanifold 110 also functions to contain (e.g., enclose, mechanicallyprotect) system components, such as the actuator(s) 120 and the pressuresensor(s) 130. The manifold 110 can also function as a substrate (e.g.,mounting point) for attachment of system components (e.g., theelectronics module 140, the cover 150, etc.) or external components(e.g., a vehicle 400). The manifold 110 is preferably made of athermoplastic (e.g., nylon or polyvinyl toluene with a 30% glass fill),but can alternatively be made of another synthetic or natural polymer,metal, composite material, or any other suitable material. The manifold110 is preferably injection-molded, but can alternatively be milled outof a single block of material (e.g., metal, plastic), cast out of metal,composed of separate sub-components which are fastened together, or madeusing any combination of these or other suitable manufacturingtechniques. One or more variations of the manifold 110 can also omit oneor more of the above elements, as well as provide a plurality of one orsnore of the above elements, in providing a suitable manifold 110.

In some variations, the manifold 110 can include webbing between one ormore molded-in ports 111, to enhance the injection-moldability of themanifold 110 while maintaining the structural integrity of thepressurized portions of the manifold 110, including the ports 111. Asshown in FIG. 5, the cross section of the manifold 110 can also includea ridge 117 a along an outer edge of the manifold 110, which canfacilitate sealing of the manifold 110 to the cover 150. However, themanifold 110 can include any other suitable set of features.

2.1.1 Ports

The manifold 110 preferably includes one or more ports 111. The port 111functions to fluidly connect a single attached service to the manifold110. The port 111 can also function to receive an external fitting(e.g., a threaded quick-release compressed-gas fitting) that facilitatesfluid connection of the port 111 to an attached service. The port 111can additionally function to fluidly connect a system inlet (e.g., thefilter) to the service, a second service to the service, or provide anyother suitable fluid connection between a first and second endpoint. Theport 111 preferably defines an open first end, open second end, and aflow axis extending between the first and second ends. However, thefirst end and/or second end can be closed or otherwise configured. Theport 111 preferably defines a straight flow axis, but can alternativelydefine a curved flow path, a branched flow path (e.g., with at least athird end in addition to the first and second end), or any othersuitable path along which air can flow through the port 111. Invariations including a plurality of ports 111, the flow axis of eachport 111 is preferably parallel to each of the other flow axes of eachof the other ports 111. In one example, the first and second ports 111are arranged with the respective flow axes sharing a common plane (portplane). However, multiple ports 111 can be arranged offset from eachother, at a non-zero angle to each other, or be arranged in any othersuitable configuration.

The port 111 can additionally define a receiving region 112, whichfunctions to seal against the barrel 122 of each actuator 120, which canprevent uncontrolled fluid communication between the channel 114 and theport 111. The receiving region 112 is preferably a constriction of theport 111 (e.g., a constriction of the inner port diameter), but canalternatively be a substantially flat ridge, boss, or any other suitablereceiving surface or region of the port 111 extending radially inwardinto the port lumen, The receiving region 112 is preferably positionedat or near the second end of the port 111 (e.g., between the first andsecond ends, proximal the second end), but can alternatively bepositioned in any suitable location along the flow axis of the port 111.The port 111 can include one or more receiving regions 112 along theport length.

2.1.2 Pressure Sensor Ports

The manifold 110 preferably includes one or more pressure sensor ports113, which function to receive one or more pressure sensors 130. Thepressure sensor ports 113 can additionally function to fluidly connectthe pressure sensors 130 with at least one of the ports 111 and/or thechannel 114. The pressure sensor port 113 can be fluidly connected tothe first port, second port, channel 114, or to any other suitable lumenby a fluid connection defined through the manifold thickness, whereinthe fluid connection can be selectively formed after manifoldmanufacture (e.g., by a vertical drilling operation to remove theinterposing manifold thickness), formed during manifold manufacture(e.g., with an injection molding insert), or otherwise formed at anyother suitable time. The remaining manifold thickness preferablyseparates (e.g., fluidly isolates) the pressure sensor port from theother lumens. In some variations, the pressure sensor port 113 can onlybe simultaneously fluidly connected to one of the ports 111 or thechannel 114. Alternatively, the pressure sensor port 113 can besimultaneously fluidly connected to multiple of the ports 111 and/orchannel 14. However, the pressure sensor port can otherwise selectivelypermit pressure sensor access to one or more of the ports 111 or channel114.

The pressure sensor port 113 can define a sensor insertion axis, alongwhich a pressure sensor 130 can be inserted. The pressure sensor port113 preferably includes a set of walls extending along the sensorinsertion axis (e.g., extending perpendicular the port axes), but canalternatively remain substantially flush with the port 111 exterior. Thewalls preferably do not extend beyond the port 111 apex, but canalternatively extend beyond the port 111 apex or extend any othersuitable distance. The pressure sensor port is preferably arrangedadjacent a port 111 (e.g., with the sensor insertion axis offset fromthe port central axis), more preferably overlapping a port 111, but canalternatively be arranged over a port 111 (e.g., with the sensorinsertion axis substantially aligned with the port central axis), or bearranged in any other suitable orientation relative to the port. Thepressure sensor port 113 is preferably arranged with the sensorinsertion axis perpendicular to the flow axes of the respective ports111 to which the pressure sensor port 113 is adjacent (e.g.,perpendicular to the port plane), but can alternatively be oriented inany suitable angle, direction, or orientation. An example configurationof the pressure sensor port 113 in relation to one or more of the ports111 is shown in FIGS. 6A and 6B. The pressure sensor port is preferablyarranged proximal the second end of the port, more preferably in aregion overlapping or coinciding with the channel 114, but canalternatively be arranged along any other suitable portion of the portlength. The pressure sensor port 113 preferably includes one or moremolded in snaps 118, which function to retain the pressure sensors 130in the pressure sensor ports 113. Alternatively, the snaps 118 can beseparate from the pressure sensor port 113, or omitted entirely.Preferably, the snaps 118 are molded into the manifold 110, but canalternatively be defined by the manifold 110 in any suitable manner,affixed to the manifold 110 after initial fabrication of the manifold asseparate components, or provided in any other suitable manner.

In one example, the pressure sensor port is arranged between an adjacentfirst and second port 111, proximal the respective second ends. Thepressure sensor port overlaps a region encompassing a portion of thefirst port 111, second port 111, and the channel 114. This configurationcan enable the same manifold 110 to be reconfigurable for variousdesired pressure sensing configurations depending on user or systemrequirements, and foregoes the need for complex porting between thepressure sensor ports 113 and the pressurized region of interest.However, the pressure sensor port can be arranged in any other suitablelocation.

The pressure sensor port 113 can additionally include internal dividersthat function to guide fluid connection formation (e.g., delineate wherethe holes should be drilled to connect the pressure sensor port 113 tothe respective lumen). The internal dividers can additionally include agroove, channel, or other seating mechanism that functions to alignand/or retain the pressure sensor tip. The internal dividers arepreferably recessed relative to the pressure sensor port walls, but canalternatively be coextensive with the walls, extend beyond the walls, orhave any other suitable height. In one variation, the pressure sensorport 113 can include three internal dividers arranged in a planesubstantially parallel the port plane, wherein the first internaldivider extends parallel the wall dividing a first and second adjacentport 111, the second internal divider extends parallel an interfacebetween the channel 114 and the first port 111, and the third internaldivider extends parallel an interface between the channel 114 and thesecond port 111. In a second variation, the first internal dividerextends parallel the wall dividing a first and second adjacent port 111,and the second and third internal dividers meet the first internaldivider at a first end and are substantially evenly radially distributedrelative to the first internal divider (e.g., wherein the first, second,and third internal dividers are separated by 120°). However, thepressure sensor port 113 can include any suitable number of internaldividers arranged in any suitable configuration.

2.1.3 Channel (Galley)

The manifold 110 preferably includes a channel (galley) 114, whichfunctions to contain a reservoir of compressed air that issimultaneously accessible to each of the actuators 120. The channelpreferably intersects the first and second ports 111 between therespective first and second ends of each port, but can alternatively beconnected by a secondary manifold or otherwise connected to one or moreports of the manifold 110. The channel 114 is preferably fluidlyconnected to every port 111 of the manifold 110, but can alternativelybe connected to a first subset of ports 111 and fluidly isolated from asecond subset of ports 111. The channel 114 preferably extends normalthe port 111, but can alternatively extend parallel to or at any othersuitable angle to the port 111. The channel 114 preferably lies in thesame plane as the ports 111, but can alternatively be offset from theport plane (e.g., lie above or below the port plane, extend at an angleto the port plane, etc.). The channel is preferably substantially linear(e.g., define a substantially linear flow axis), but can alternativelybe curved (e.g., toward or away from the second end, out from the portplane, etc.) or have any other suitable configuration. However, thechannel can be otherwise configured or arranged.

The channel 114 is preferably molded directly into the manifold 110, butcan alternatively be drilled, milled, or otherwise manufactured into themanifold 110. The channel 114 is preferably connected to an output of afilter 160, but can alternatively be connected directly to an input. Thechannel 114 preferably has a substantially constant cross-section alongits length, but can alternatively have a variable cross-section. Thechannel diameter is preferably substantially the same as (or on theorder of) the port diameter, but can alternatively be larger or smaller.The channel can have a circular cross section, an obloid cross section,or have any other suitable cross-section. However, the channel can haveany other suitable configuration.

The channel 114 is preferably configured such that the pressureeverywhere in the channel 114 is substantially the same regardless ofwhether or not one or more of the actuators 120 is in a position thatfluidly connects the channel 114 to one or more of the ports 111. Thisconfiguration can be achieved, for example, by a passthrough region 114′(passover region, passaround region, etc.) as shown in FIG. 10. Thepassthrough region can be cooperatively defined by the channel lumen(having a substantially constant cross-section throughout its length)and a constricted portion of the actuator 120 (e.g., constricted alongan axis normal to the port plane, constricted radially, etc.), upstreamfrom the barrel, which coincides with the channel 114 when the actuator120 is in the closed position. Alternatively, the passthrough region canbe defined as an outcropping along the length of the channel lumen.However, the passthrough region can be otherwise defined. Alternatively,sections of the channel 114 can be selectively sealed off when theactuators 120 are closed, or operate in any other suitable manner.

2.1.4 Cavity

The manifold 110 preferably includes a cavity 115, which functions toreceive the actuator(s) 120 and to coaxially align the actuator(s) 120with the port(s) 111. In variations of the system 100 employing apotting compound to reduce vibration and enhance structural rigidity ofportions of the system 100, the cavity 115 can also function to receivethe potting compound. The cavity 115 preferably includes a surface thatis lower than the lowermost edge of the ports 111 (e.g., recessedrelative to the ports, substantially parallel the nadir of the ports,etc.), as shown in FIG. 4, but can alternatively include a surfaceparallel to a chord of the port cross section (e.g., impinges on theport cross section) or arranged in any other suitable location relativeto the ports. The recessed surface can function to receive actuator(s)120 that have a larger diameter than the respective port 111. The cavity115 can also include a number of sub-cavities, each sub-cavityconfigured to receive a single actuator 120 and separated from anadjacent sub-cavity by a divider protruding from the surface, asdepicted by example in FIGS. 9 and 13. The cavity 115 is preferablycontiguous with the ports 111, but can alternatively be otherwiserelated to the ports. In one example, the cavity intersects the secondend of the ports 111.

2.1.5 Pilot Ports

As shown in FIG. 17, the manifold 110 can additionally include one ormore pilot ports 116, which function to fluidly connect the port(s) into a second stage manifold 170 and permit the actuator(s) 120 tomodulate airflow through the second stage manifold 170. Preferably, thepilot port(s) 116 are arranged with a longitudinal axis (e.g., flowaxis) extending out of the plane shared by the flow axes of theport(s)(e.g., at an angle to the port plane, normal to the port plane,etc.), such that the second stage manifold 170 does not extendsubstantially outside the broadest projected area of the manifold 110when the second stage manifold 170 is coupled to the manifold 110.Alternatively, the pilot port(s) 116 can be arranged in any suitableorientation, and configured in any suitable manner.

2.1.6 Internal Support Features

The manifold 110 can additionally include one or more internal supportfeatures 117, which function as registration and/or alignment featuresfor aligning and properly orienting internal components (e.g., anactuator 120). The internal support features 117 can also function asload-bearing members of the manifold 110 that dampen, absorb, and/orprovide reaction forces to dynamic components (e.g., actuators 120)during operation, in order to reduce wear on the system 100. As shown inFIG. 4, an internal support feature 117 can include a ridge thatcooperates with other portions of the cavity 115 in receiving theactuator(s) 120, The internal support features 117 can additionally oralternatively include any suitable features that mechanically configureportions of the system 100 within the manifold 110 and/or providemechanical support to portions of the system 100. The manifold 110 canadditionally include a valve retainer 119, which functions to retain theactuators 120 within the cavity 115 and hold them in place. The valveretainer 119 is preferably molded into the manifold 110, but canalternatively be inserted, fastened, or otherwise coupled to themanifold 110 in any suitable manner. Alternatively, the valve retainer119 can be omitted entirely.

2.1.7 Manifold Examples

In an example embodiment, the manifold 110 defines a first and secondport in, each port 111 defining a flow axis extending between a firstand second end of the port 111. Each port 111 also defines a receivingregion 112 at the second end. Each of the flow axes are arranged in acommon plane, with each of the flow axes parallel to one another. Themanifold 110 additionally defines a channel 114, intersecting the firstand second port in between the first and second ends of each port 111.The manifold 110 additionally defines a cavity 115, which intersects thesecond end of each port 111, forming a void intended to receive anactuator 120. The manifold 110 additionally defines a pressure sensorport 113, positioned between the first and second port 111, whichdefines a sensor insertion axis normal to the common plane. The pressuresensor port 113 is separated from the first port 111, the second portand the channel 114 by a thickness of the manifold 110. The thicknesscan be specified by the mold from which the manifold 110 is made byinjection-molding, The thickness of the manifold 110 can be removed(e.g., drilling) between the pressure sensor port 113 and any one of thefirst port 111, the second port 111, and the channel 114, in order tofluidly connect two of these regions. This fluid connection allows apressure sensor 130, arranged in the pressure sensor port 113, to make acontact pressure measurement of the pressure in any one of the firstport 111, the second port 111, and the channel 114.

2.2 Actuator

As shown in FIG. 1, the actuator 120 of the system 100 can include abarrel 122, a body 124, and a connector 126. The actuator 120 functionsto selectively bring the channel 114 into fluid communication with theport 111 to which the actuator 120 is coupled. In one variation, theactuator 120 is selectively operable between an open position, whereinthe actuator 120 permits fluid connection between the respective port inand the channel 114, and a closed mode, wherein the actuator 120 ceases(e.g., prevents) fluid flow between the respective port 111 and thechannel 114. Actuator operation can be actively controlled by theelectronics module, passively controlled, or otherwise controlled by anyother suitable control system. The actuator 120 is preferably at leastpartially housed by the manifold, but can alternatively be arrangedexternal the manifold (e.g., in variants where the manifold only definesthe ports 111 and the pressure sensor ports 113), or be arranged in anyother suitable location relative to the manifold.

The actuator 120 can define an actuation axis, wherein the actuator 120can be arranged within the cavity 115 such that the actuation axis isparallel (more preferably collinear or coaxial, but alternatively in anysuitable configuration) with the flow axis of the first port 111.However, the actuator 120 can be arranged with the actuation axis at anysuitable angle to the flow axis of the port. The actuator 120 ispreferably configured to regulate the flow of a pressurized fluidbetween the channel 114 and the first end of the first port 111, but canalternatively regulate pressurized fluid flow between a first and secondport, or regulate pressurized fluid flow in any other suitable flowpattern.

actuator 120 operation in the open position preferably permitspressurized air to pass from the channel 114 to the port 111, and fromthat point onwards to any service attached to the port 111. Actuatoractuation to the open position is preferably performed under the directinfluence of the electronics module go, which itself may beautonomously, semi-autonomously, or manually controlled. The systempreferably includes a plurality of actuators 120, but alternativelythere can be only a single actuator 120. Each actuator 120 is preferablyconnected to and regulates a different port 111, but multiple actuators120 can alternatively be connected to and regulate a single port 111, asingle actuator 120 can be connected to and regulate multiple ports 111,or the system can include any other suitable actuator 120 and port 111configuration.

Each of the actuators 120 is preferably oriented parallel to the portplane, but can alternatively be arranged at an non-zero angle to theport plane, arranged perpendicular the port plane, or otherwisearranged. Each actuator 120 is preferably coaxially aligned with arespective port 111, but can alternatively be offset from the respectiveport or otherwise arranged.

The actuator 120 is preferably a solenoid valve, examples of whichinclude a two-way direct acting solenoid valve, a two-waypressure-balanced solenoid valve, and a three-way solenoid valve. Thesolenoid valve can have one of a set of orifice sizes (e.g., a 2 mmorifice, a 4 mm orifice, and a 0.5 mm orifice) that governs the maximumflow rate through the solenoid valve between the channel 114 and theport 111 during actuation, for a given pressure in the channel 114. Theactuator 120 can alternatively be any suitable linear or rotary actuatorthat enables electromechanical control of fluid communication betweenthe channel 114 and one or more of the ports 111. The actuator 120 ispreferably controlled by the electronics module 140 using a pulse-widthmodulated (PWM) signal, but can alternatively be controlled using ananalog signal, a digital signal, an amplified analog or digital signal,or any other suitable electronic control scheme.

The barrel 122 is preferably a cylindrical portion of the housing of theactuator 120, as shown in FIG. 18. The barrel 122 functions to seal theactuator 120 against the manifold 110, preferably at the receivingregion 112 but alternatively any suitable portion of the port 111 ormanifold 110. The barrel 122 can include a void as shown in FIG. 18,which permits the channel 114 to fluidly couple to the port 111 when theactuator 120 is in the open position. The barrel 122 can additionallyinclude a constriction, as shown in FIG. 18, which permits the channel114 to remain fluidly contiguous independently of the actuation of theactuator(s) 120. The barrel 122 is preferably sealed against themanifold 110 using one or more elastomeric ring-type seals emplaced incircumferential external grooves in the surface of the barrel 122, asshown in FIG. 18. Alternatively, the barrel 122 can be sealed using apress-fit, a weld, an airtight epoxy, a gasket, or using any othersuitable seal.

The body 124 is preferably the bulk of the housing of the actuator 120,excepting the barrel 122, and functions to contain the other portions ofthe actuator 120 (e.g., a solenoid, a solenoid core, mechanicalsupports, etc.). The body 124 can be of an open-frame configuration thatis unpressurized (e.g., at atmospheric pressure), due to the seal of thebarrel 122 against the manifold 110. The body 124 of each actuator 120is preferably housed in the cavity 115 of the manifold 110, and can beretained in the cavity 115 by one or more internal support features 117of the manifold 110. Alternatively, the body 124 can be retained in asub-cavity of the cavity 115, each sub-cavity configured to firmlycouple to and retain the body 124 of a single actuator 120.Alternatively, the body 124 can be mounted to the manifold (e.g., byscrews, straps, adhesive, etc.). However, the body can be otherwisecoupled to the manifold. The body is preferably coaxially arranged withand actuatably coupled to the barrel, but can alternatively be offsetfrom the barrel, decoupled from the barrel, or otherwise arrangedrelative to the barrel.

The connector 126 preferably electrically couples the actuator 120 tothe electronics module 140, and functions to provide controllable powerto the actuator 120 and to decouple mechanical and/or thermal loads ofthe actuator 120 from the electronics module 140. Each actuator 120preferably includes a single connector, but can alternatively includemultiple connectors. Connectors are preferably not shared betweenactuators, but can alternatively be shared between actuators (e.g.,wherein the connectors are connected to a common rail, wherein theactuators are connected to the common rail). When the actuator isassembled to the manifold, the connectors preferably extend normal tothe port plane, away from the cavity surface. Alternatively, theconnectors can extend parallel to the port plane, at a non-zero angle tothe port plane, or extend in any other suitable direction. In examplevariations, the connector 126 can be an articulated linkage, a wire, asoldered connector, a spring-loaded connector, a flying lead with anassociated plug, or any suitable connection that electrically couplesthe actuator 120 to the electronics module 140 while maintainingmechanical and thermal isolation between the actuator 120 and theelectronics module 140. However, the connector 126 can be a pin,soldered junction, male/female connector, or be any other suitableconnector.

One or more variations of the actuator(s) 120 can also omit one or moreof the above elements, as well as provide a plurality of one or more ofthe above elements, in providing a suitable actuator 120.

In an example embodiment, the system 100 includes a first and secondactuator, wherein the first and second actuators are a first and secondsolenoid valve, respectively. Each solenoid valve is arranged within thecavity 115 and coaxially arranged with the first and second ports 111,respectively. Each solenoid valve includes a set of connectors 126. Theconnectors 126 of each solenoid valve extends perpendicularly away fromthe common plane of the flow axes of the ports 111 of the manifold 110,and towards the electronics module 140. Each solenoid valve 120preferably includes a valve barrel that is configured to seal againstthe receiving region of the corresponding port 111.

2.3 Pressure Sensor

As shown in FIGS. 1 and 14, the system 100 includes a pressure sensor130. The pressure sensor 130 functions to measure a signal indicative ofthe air pressure in one of several portions of the manifold 110 (e.g.,in the pressure sensor port, the channel 114, the port 111, etc). Thepressure sensor 130 can also function to enable control of theactuator(s) 120 based on pressures detected by the pressure sensor 130.The pressure sensor 130 is preferably arranged in a pressure sensor port113, wherein the pressure sensor port 113 has preferably been“activated” (i.e., a fluid connection has been installed between one ormore of the ports 111, the channel 114, and the pressure sensor port)prior to assembly of the pressure sensor 130 in the pressure sensor port113. One or more variations of the pressure sensor(s) 130 can also omitone or more of the above elements, as well as provide a plurality of oneor more of the above elements, in providing a suitable pressure sensor130.

The pressure sensor 130 is preferably a single point pressure transducerthat outputs an electrical signal proportional to the pressure of aregion of physical space that is fluidly connected to the pressuresensor 130. However, the pressure sensor 130 can be any other suitablepressure sensor. Examples of the types of pressure that can be measuredinclude: absolute pressure, gauge pressure, vacuum pressure, anddifferential pressure. Alternatively, the pressure sensor 130 canmeasure any suitable type of pressure. The pressure sensor 130 can sensethe pressure by sensing one or more of: piezoresistive strain, thepiezoelectric effect, a capacitive change, an inductance change, theHall effect, eddy currents, electromagnetic disturbances, an opticalpath length change, a resistance change, a change in displacement, achange in resonant frequency, an ionization fraction, and a change inthermal conductivity. Alternatively, the pressure sensor 130 can sensethe pressure by sensing any other suitable parameter of the fluid or ofa container of the fluid. In an example embodiment, the pressure sensor130 has a protrusion along the insertion axis of the pressure sensor 130into the pressure sensor port 113, and additionally includes a radialseal between the protrusion and the pressure sensor port 113. Inalternative variations, the pressure sensor 130 can seal against thepressure sensor port 113 in any suitable manner.

The pressure sensor 130 can additionally include a connector 132. Theconnector 132 functions to electrically couple the pressure sensor 132to the electronics module 140, providing a conduit for power and/or datatransfer. The connector 132 is preferably an electrical connector, butcan alternatively be any other suitable connector. The connector 132preferably includes a set of electrical leads, but can alternativelyinclude a set of conductive linkages or have any other suitableconfiguration. The connector 132 can be rigid or flexible. The connector132 preferably extends normal to the port plane, away from the pressuresensor 130 and/or manifold, but can additionally or alternatively extendtowards the electronics module 140, as shown in FIG. 15, extend parallelto the connector 126 of the actuator 120, or be arranged in any suitablemanner. In an example embodiment, the connector 132 is a set ofelectrical leads, rigidly connected to the pressure sensor 130, each ofthe set of electrical leads extending perpendicularly away from theshared plane of the flow axes of the ports 111 and towards theelectronics module 140.

2.4 Electronics Module

The electronics module 140 of the system 100 functions as an electroniccommand and control interface between the actuator(s) 120, the pressuresensor(s) 130, and other input or output electronic signals. Theelectronics module 140 can additionally cooperatively enclose theactuator(s) 120 and the pressure sensor(s) 130 within the manifold 110.The electronics module can additionally function to control powerprovision to the connected components. As shown in FIG. 1, theelectronics module 140 can include an electronics substrate 142, adisplacement sensor 144, an input/output module 146, a processor 148,and an external connector 149.

The electronics module 140 is preferably electrically connected to andcontrols the operation of the connector(s) 132 of the pressure sensor(s)130 and the connectors) 126 of the actuator(s) 120. Alternatively,another control module can control one or all of the pressure sensorsand actuators. The electronics module 140 is preferably a printedcircuit board assembly (PCB), with the abovementioned elements wholly orpartially mechanically supported and electrically connected to the PCB,but can alternatively be configured as a wire wrap circuit, apoint-to-point soldered electrical circuit, or any other suitableconfiguration. One or more variations of the electronics module 140 canalso omit one or more of the above elements, as well as provide aplurality of one or more of the above elements, in providing a suitableelectronics module 140.

The electronics substrate 142 functions as a physical attachment pointfor portions of the actuator(s) 120, the pressure sensor(s) 130, andother elements of the system 100 requiring an electronic interface. Thefootprint of the electronics substrate 142 preferably substantiallymatches that of the manifold, but can alternatively be smaller (e.g.,extend over the pressure sensor ports and the actuator connectorlocations, etc.), or larger. The electronics substrate 142 is preferablymounted to the manifold 110 distal the cavity surface, but canalternatively be mounted along any other suitable portion of themanifold 110 or system 100. The electronics substrate 142 is preferablymounted to the manifold parallel the port plane, such that theconnector(s) 132 and the connector(s) 126 substantially perpendicularlyconnect to the electronics substrate 142, but can alternatively mount tothe manifold in any other suitable orientation. However, the electronicssubstrate 142 can be mounted to the manifold 110 in any other suitableconfiguration, The electronics substrate 142 can be mounted to themanifold 110 using a set of screws, clips, adhesive, or any othersuitable mounting mechanism. The electronics substrate 142 is preferablymade of a phenolic resin or other non-conductive material, andpreferably includes one or more embedded copper layers, in forming aportion of a printed circuit board. Alternatively, the electronicssubstrate 142 can be composed of any suitable material that providesmechanical support to elements of the electronics module 140.

The displacement sensor 144 of the electronics module functions todetect and report a displacement measurement. A displacement measurementpreferably includes a measurement of the relative distance or movementbetween the system 100 and a portion of a vehicle 100, but canadditionally or alternatively include an absolute distance measurement,a motion measurement, or any other suitable measurement. For example,the displacement sensor 144 can detect the relative movement of thesystem 100 with respect to a strut of a vehicle suspension (e.g., system100 rise relative to the strut), and transmit a quantitativerepresentation of the raising of the system 100 to other portions of theelectronics module 140 or coupled electronic systems. The displacementsensor 144 is preferably an array of Hall-effect sensors that isconfigured to sense the relative displacement of a magnet 144 b, coupledto the chassis of a vehicle 400 using a bracket 144 c as depicted inFIG. 7. The displacement sensor 144 can alternatively be any form ofnon-contact displacement sensor. As a further alternative, thedisplacement sensor 144 can be any suitable sensor capable of detectingthe movement and/or displacement of the system 100. The displacementsensor 144 is preferably arranged along a broad face of the electronicssubstrate 142 opposing (e.g., distal) the manifolds and/or actuators,but can alternatively be arranged along the broad face proximal themanifolds and/or actuators, be arranged on the manifold, or be arrangedin any other suitable location. The electronics module 140 can includeone displacement sensor 144 per strut; one displacement sensor 144 permanifold; one displacement sensor 144 per actuator; multipledisplacement sensors 144 per strut, manifold, or actuator; onedisplacement sensor 144 for multiple struts, manifolds, or actuators; orinclude any suitable number of displacement sensor 144 configured tocouple to and/or monitor any other suitable system component. However,the electronics module 140 can include and/or be connected to any othersuitable set of sensors.

The input/output (I/O) module 146 of the electronics module 140functions to route (transmit, receive, transfer) any electronic signalsreceived or generated by the electronics module 140 to other portions ofthe electronics module 140 or to electrically connected externalsystems. The I/O module 146 can include a communicator (e.g., a wired orwireless transceiver) and a connector (e.g., on-board data connection,on-board power connection, off-board data connection, off-board powerconnection, etc.), but can alternatively or additionally include anyother suitable set of components. The I/O module 146 can also interfacewith buttons, switches, lights, speakers, microphones, levers, or anyother suitable input and output mechanisms in providing a communicationinterface between the electronics module 140 and other portions of thesystem 100 and/or connected external systems.

The processor 148 of the electronics module 140 functions to providecomputing resources to the electronics module 140, and can also functionto entirely or partially control portions of the system 100 (e.g., theactuators) 120). The processor 148 preferably executes command andcontrol instructions received from an externally connected system, butcan additionally or alternatively execute such instructions generatedinternally and cooperatively by elements of the system 100, or incombination with an externally connected system. The processor 148 canbe a CPU, GPU, microprocessor, or any other suitable processor. Thesystem can include one or more processors 148.

The external connector 149 of the electronics module 140 functions as aphysical electronic interface between an externally connected system(e.g., the vehicle) and the electronics module 140. As shown in FIG. 10,examples of an external connector 149 can include specific male and/orfemale electrical pin arrangements, as well as a housing to facilitateproper coupling of the external connector 149 with mating components.One or more pins of the external connector 149 are preferablyelectrically coupled to the electronics substrate 142, in order tofacilitate transfer of electrical signals between the external connector149 and other portions of the electronics module 140. At least certainsegments of the pins of the external connector 149 preferably extend ina parallel direction to the connector(s) 126 and the connector(s) 132,such that the pins, connector(s) 126, and connector(s) 132 all intersectthe plane of the electronics substrate 142 while extended along the samedirection. Alternatively, the pins of the external connector 149 can beconnected to flexible wires, or rigidly extend in any suitabledirection. The external connector 149 can extend outside of the housing(cooperatively formed by the manifold and cover), terminate flush withthe exterior surface of the housing, extend beyond the housing, orextend to any other suitable endpoint.

In an example embodiment, the electronics module 140 is arrangedparallel to the common plane of the flow axes of the ports 111 of themanifold 110. The electronics module 140 and the manifold 110cooperatively enclose the first solenoid valve 120 a, the secondsolenoid valve 120 a, and the pressure sensor 130. The electronicsmodule 140 is configured to receive and electrically couple to theelectrical leads of the pressure sensor 130, the connector 126 of thefirst solenoid valve 120 a, and the connector 126 of the second solenoidvalve 120 a. The electrical leads and connectors are preferably solderedto the electronics substrate 142 of the electronics module 140, but canalternatively be otherwise electrically and/or physically connected tothe electronics substrate 142.

2.5 Cover

As shown in FIG. 10, the cover 150 can include a pressure sensor support152, an electronics retainer 154, a connector housing 156, a seal 158,and a manifold retainer 159. The cover 150 functions to cooperativelydefine a housing with the manifold 110, wherein the housing encloses theactuator(s) 120, the pressure sensor(s) 130, and the electronics module140. The cover 150 can also function to form a fluid impermeable sealagainst the manifold 110, such that the system 100 (e.g., housing) canmaintain a positive internal pressure. Alternatively, the housing can besubstantially fluid permeable. In some variations, the lumen definedbetween the cover 150 and the manifold 110 can be wholly or partiallyfilled with a potting compound.

The cover can define a broad face, longitudinal axis, thickness (e.g.,perpendicular the broad face), or any other suitable dimension orcomponent. In one variation, the cover is configured to mount to themanifold with the cover broad face substantially parallel a manifoldbroad face. In a second variation, the cover is configured to mount tothe manifold with the cover broad face perpendicular a manifold broadface (e.g., with the cover broad face perpendicular the manifoldlongitudinal axis). However, the cover can couple to the manifold in anyother suitable manner.

The pressure sensor support 152 of the cover 150 functions to counteractpressure force exerted on the pressure sensor 130. The pressure sensorsupport 152 preferably prevents the electronics module 140 fromexperiencing stress and/or strain that can result from a pressure forceexerted on the pressure sensor 130. The pressure sensor support 152 ispreferably a scaffold, extending at least partially from the internalsurface of the cover 150, and includes at least one post substantiallyaligned with and extending towards a corresponding pressure sensor 130,pressure sensor mounting point on the electronics substrate 142, and/orpressure sensor port. However, the posts can be otherwise arranged. Thecover preferably includes one post for each pressure sensor port, butcan alternatively include any suitable number of posts. The cover canalternatively include any other suitable mechanical mechanism in lieu ofa post for applying a reaction force to the pressure sensor 130 (e.g., aspring). The pressure sensor support 152 can alternatively be integratedwith the pressure sensor port 113 of the manifold 110, e.g., as a set ofsnaps, as shown in FIG. 21. The post preferably abuts a surface of thepressure sensor 130, more preferably an end of the pressure sensordistal the manifold, but can alternatively be separated from thepressure sensor 130, or be otherwise arranged relative to the pressuresensor. In the variation in which the post abuts the pressure sensor,the post can provide a force path between the pressure sensor 130 andthe cover 150, thereby circumventing the electronics module 140 (e.g.,prevent the pressure sensor 130 movement from substantially deformingthe electronics module 140). Alternatively, any other suitable structureof the cover 150 can provide the described force path, in routing thepressure force away from the electronics module 140 and electronicssubstrate 142. The post end proximal (e.g., abutting) the pressuresensor 130 preferably has a larger surface area than the pressure sensorend, but can alternatively have a smaller surface area or any othersuitable surface area. The post end proximal the pressure sensor can bebare, include a set of dampening mechanisms (e.g., springs, foam, etc.),or include any other suitable component.

The electronics retainer 154 of the cover 150 preferably functions tosecurely hold the electronics substrate 142 in position (e.g., retainthe electronics substrate), as shown by example in FIG. 14. The retainer154 is preferably one or more snaps, into which the electronicssubstrate 142 can be pressed, slid, clipped, or otherwise removablyfastened. The electronics retainer 154 can alternatively be any otherform of removable or permanent fastening subsystem or component thatsuitably retains the electronics substrate 142 and/or the electronicsmodule 140 in the void between the cover 150 and the manifold 110. Inanother specific example, the electronics retainer 154 is integratedwith (e.g., molded into, defined by, fastened to) the manifold 110, andis not part of the cover 150. In a variation of this specific example,the electronics substrate 142 is snapped into the manifold 110 and doesnot interface with the cover 150. Alternatively, the system 100 omitsthe electronics retainer 154.

The connector housing 156 of the cover 150 functions to protect theelectrical interface of the external connector 149, as well as tofacilitate manual coupling and decoupling of external systems to theexternal connector 149. The connector housing 156 is preferably a bossextending from the cover 150 around the external connector 149, and caninclude one or more grooves, snaps, ridges, and similar features tofacilitate coupling as described. The connector housing 156 can extendperpendicular the cover broad face, parallel the cover broad face, or inany other suitable direction at any suitable angle. An example connectorhousing 156 is depicted in FIG. 14. In a specific example, the connectorhousing 156 is molded into the manifold 110 instead of the cover 150. Inanother specific example, portions of the connector housing 156 aredefined by the cover 150, and separate portions of the connector housing156 are defined by the manifold 110, the two portions cooperativelydefining the connector housing 156.

The seal 158 of the cover 150 functions to prevent uncontrolled fluidcommunication between the exterior and interior of the housing. The seal158 preferably facilitates the internal pressurization of the coupledcover and manifold 110, though the coupled cover 150 and manifold 110may not be entirely or partially pressurized during normal operation.The seal 158 preferably extends along the entirety of the junctionbetween the manifold and the cover, but can alternatively extend along aportion of the junction or be arranged in any other suitable location.In variations in which the void between the cover 150 and manifold 110is filled or partially filled with a potting compound, the seal 158 canfunction to retain the potting compound within the void. The seal 158 ispreferably an elastomeric ring, emplaced along a raised boss of eitherthe manifold 110 or cover 150, as illustrated by example in FIG. 10.Alternatively, the seal 158 can be a weld joint, an epoxy layer, agasket, or any other suitable seal between the cover 150 and themanifold 110. The seal 158 can additionally or alternatively include aplurality of seals 158 or sealed regions, located at any portion of themanifold 110 or cover 150 that includes a hole, leak path, opening,joint, or any other region or orifice through which fluid can pass.

The manifold retainer 159 of the cover 150 functions to retain the cover150 against the manifold 110. In some variations, the manifold retainer159 is one or more snaps that allow the cover 150 to be clipped(snapped, press-fit) to the manifold 110. In other variations, themanifold retainer 159 can be a set of bolts, screws, nuts, and/or holesthat cooperatively fasten the manifold 110 to the cover 150. In stillfurther variations, the manifold retainer 159 is a weld joint betweenthe cover 150 and the manifold 110. The manifold retainer 159 canadditionally or alternatively include a combination of removable andpermanent coupling mechanisms and/or fasteners, or any other suitabledevice for retaining the cover 150 against the manifold 110. In aspecific example, the cover 150 is welded to the manifold 110,preferably by plastic welding (e.g., ultrasonic welding, hot platewelding, linear vibration welding, etc.), but alternatively by anysuitable form of welding or means of affixing the cover 150 to themanifold 110.

2.6 Fitter

The system 100 can optionally include a filter 160 which can include aninput 161, a filter plate 162, an expansion chamber 163, a filterelement 164, and an exhaust 165. The filter 160 functions to processpotentially moist, dirty air from a compressor and provide clean, dryair to the manifold 110. The filter 160 preferably defines an inlet(input 161) and an outlet. The inlet is preferably connected to theambient environment, but can alternatively be connected to a pump, afluid source, or any other fluid source. The filter outlet is preferablyfluidly connected to the manifold 110, more preferably the channel 114,but can alternatively be fluidly connected to the manifold ports, theactuator, the housing interior, or to any other suitable endpoint. Insome variations, portions of the filter 160 are defined by the manifold110, as depicted in FIG. 5. The filter 160 is preferably an integrated,coalescing, self-purging filter. A coalescing filter can be a filterthat includes a region of porous, absorbent material that creates atortuous path for air flowing through the region. This tortuous paththrough the material preferably causes moisture to be absorbed into thematerial, and wicked towards the edge(s) of the region to be excretedfrom the region and subsequently expelled from the filter.Alternatively, a coalescing filter can be any other suitable filter thatcoalesces fluid (e.g., liquids), particulates, or other components fromthe fluid flowing there through. An integrated filter can be a filterthat is at least partially integrated with the manifold 110. However,the filter 160 can be any other suitable filter type. The filter 160 canalso include a housing, and the housing is preferably at least partiallydefined by the manifold 110 (e.g., the manifold 110 includes a chamberthat forms the expansion chamber 163 of the filter 160). A self-purgingfilter can be a filter that exhausts the condensed moisture and/orremoved particulates as a result of the airflow through the filterduring normal operation (e.g., periodically, constantly, when a pressurecondition is met, etc.). The filter 160 is preferably positionedadjacent to the cavity 115 of the manifold 110, in order to provide acompact package size of the system 100, as depicted in FIGS. 8 and 12.Alternatively, the filter 160 can be an inline filter that is indirectlycoupled to the manifold 110 by way of a compressed air line, orpositioned in any suitable location relative to the manifold 110 (e.g.,separated by a distance, in a central portion of the manifold 110,etc.). Alternatively, the filler 160 can be arranged in any othersuitable configuration.

The input 161 of the filter 160 functions to couple a fluid source, morepreferably a source of compressed air but alternatively another fluidsource, to the system too, and to provide the compressed air to otherportions of the system 100 after passing through the filler 160. Theinput 161 can include a fitting, configured to couple to a standardizedair hose, air compressor, or similar. The input 161 can also be separatefrom the filter 160, and can additionally or alternatively be includedin variations that do not have an integrated filter 160, as an inputpoint to the channel 114. In variations including a filter 160 withoutan expansion chamber 163 or without a filter 160, the input 161 ispreferably oriented perpendicularly to the ports 111, as shown in FIG.8. Alternatively, the input 161 can be oriented in any suitabledirection that permits coupling to the channel 114.

The filter plate 162 of the filter 160 functions to process particulatesin the compressed air entering the filter 160. Processing of theparticulates can include capturing, deflecting, absorbing, collecting,neutralizing, or any other suitable form of processing. The filter plate162 is preferably oriented normal to the inflow direction to maximizethe flux of entrained particulates at the surface of the filter plate162, but can alternatively be oriented in any suitable manner along oradjacent to the flow path through the filter 160. Particulates that canbe processed. (removed, neutralized) include water droplets, dust, sand,metallic pieces, or any other particles entrained in the airflow.

The expansion chamber 163 of the filter 160 functions to condensemoisture that may be present in the inflowing compressed air. Themoisture is preferably condensed by altering the thermodynamic state(e.g., the specific volume by way of expanding) of the inflowing airsuch that any entrained water vapor changes phase into droplets ofliquid water, which can then collect in a portion of the expansionchamber 163 for subsequent removal by the exhaust 165. This processseparates condensed moisture from the resulting dry air. However, themoisture can be condensed in any other suitable manner. The expansionchamber 163 is preferably an elongated void within the filter 160, andpreferably has a large volume relative to the volume of the inlet regionof the filter 160 in order to facilitate expansion. Alternatively, theexpansion chamber 163 can be any suitable shape and/or size.

The filter element 164 of the filter 160 functions to process impuritiesthat may remain in the inflowing air after passing through otherportions of the filter 160. Processing of the impurities can include allthe forms of processing described above with respect to the filter plate162, as well as any other suitable forms of processing. The filterelement 164 is preferably disposed between the manifold 110 and thefilter 160, such that fluid passing from the latter into the former mustpass through the filter element 164, but can alternatively be configuredin any suitable manner. The filter element 164 is preferably acoalescing filter, and preferably includes a region of fibrous andporous material through which the air is directed to pass as it flowsthrough the filter 160. Alternatively, the filter element 164 can be anactivated carbon filter, a mesh screen, or any other suitable filteringelement.

The exhaust 165 of the filter 160 functions to expel substances thathave been filtered out of the hallowing compressed air from the system100. The exhaust 165 is preferably a poppet-regulated self-actuatingexhaust, and preferably automatically expels the filtered substancesduring operation of the system 100. This can occur, for example, uponactuation of one or more of the actuator(s) 120, creating a pressuredifference within the system 100 that moves a poppet valve of theexhaust 165.

2.7 Second Stage Manifold

The system 100 can optionally include a second stage manifold 170, whichcan include a movable obstruction 172, a tube 174, and a gasket 176. Thesecond stage manifold 170 functions to provide an alternative flowsystem that is controllable based upon the airflow through the manifold110. In some variations, the second stage manifold 170 can function as ahigh-flow-rate manifold that is controlled by a low-flow-rate manifold110. The second stage manifold 170 is preferably removable andserviceable in the field (e.g., by a user of the system 100 or driver ofa vehicle 400 to which the system 100 is coupled), but can alternativelybe substantially permanent. As shown in FIG. 11, the second stagemanifold 170 is preferably coupled to the manifold 110 such that thesecond stage manifold 170 and the manifold 110 are stacked (e.g.,vertically, along the flow direction, etc.), and the flow direction ofair from the manifold 110 to the second stage manifold 170 isperpendicular to the flow direction along the ports 111 of the manifold110. However, the second stage manifold 170 can be oriented relative tothe manifold 110 in any other suitable configuration. The system caninclude one or more second stage manifolds, arranged in any suitableconfiguration.

The movable obstruction 172 of the second stage manifold 170 functionsto regulate a flow of air at a higher flow rate than is typicallydesired from the actuator(s) 120, but can alternatively regulate a loweror higher fluid flow rate. The movable obstruction can be an air-pilotedvalve, or be any other suitable valve. The air-piloted valve ispreferably a poppet valve, as illustrated in FIG. 11, and is preferablyactuated by applying a differential pressure and/or air flow to thepoppet (e.g., it is air-piloted), using, for example, the actuator(s)120. However, the movable obstruction 172 can be actively controlled orotherwise controlled. The movable obstruction 172 within the tube 174 isoperable between an open state and a closed state, based on a controlledfluid flow directed by the actuator 120.

The tube 174 of the second stage manifold 170 functions to direct airflow from a compressed air source to an output of the second stagemanifold 170, mediated by the movable obstruction 172. As shown in FIG.11, the movable obstruction 172 is preferably actuatably housed by aportion of the tube 174 and can function to alternately block and/orpermit airflow through, past, around, or otherwise traversing themovable obstruction 172. However, the movable obstruction 172 can beconnected to the tube 174 in any other suitable manner, or the movableObstruction 172 can be unconnected from the tube 174. The tube 174 ispreferably fluidly connected to a pilot port rib of the manifold 110,but can alternatively be connected to any other suitable portion of themanifold 110 or system 100.

The gasket 176 of the second stage manifold 170 functions to seal themanifold 110 against the second stage manifold 170. In particular, thegasket 176 can function to seal the pilot port(s) 116 of the manifold110 against the tube 174 and/or the air-piloted valve 172 of the secondstage manifold 170. The gasket 176 can include: a sheet gasket, a rubbergasket, a silicone gasket, a plastic gasket, a metal gasket, or anyother suitable type of gasket and/or seal.

2.8 Specific Examples of the System

In a first example of the system 100, the system 100 includes a pressuresensor support, a printed circuit board assembly (PCBA), a cover, apressure sensor, and a solenoid valve. A pressure sensor support 152′ isincorporated into the pressure sensor port of the manifold as a set ofsnaps, and retains the pressure sensor 130′ while withstanding anypressure force pushing on the pressure sensor 130′. The PCBA 140′ isretained by a set of snaps molded into the manifold. Each solenoid valve120′ forms a radial seal between a barrel 122 and a respective interiorof the injection-molded plastic port 111′. Each valve 120′ has avertically extending connector 126′, and is soldered directly to thePCBA 140′ along with each pressure sensor 120′. A connector housing 156′is molded into the manifold 110′, and includes an external connector149′. Portions of the pins of the external connector 149′ extendupwards, parallel to the connector 126′ and pressure sensor connector132′ of the valve 120′ and pressure sensor 130′, respectively. The PCBA140′ is located and retained by a number of snaps, tabs and slots 154′in the manifold 110′, and receives the pins of the external connector149′, the valve connector 126′, and the pressure sensor connector 132′in a single common plane. This enables the aforementioned pins andconnectors to be electrically connected (e.g., soldered) to the PCBA140′ in a single assembly step, without changing the orientation of theassembly. The cover 150′ is affixed to the manifold 110′ by welding, andwelding is performed by linear vibration welding. The valve 120′ can beused to actuate one or more air-piloted valves 172 in a second manifoldstage 170. Each valve 120′ is located in the cavity 115′ of the manifold110′, and has an open frame and coil assembly. The operating voltage ofthe electronics module 140′ is 8 to 16 V. However, the system caninclude any suitable set of components in any other suitableconfiguration.

In a second example of the system 100, the system 100 includes apressure sensor support, a printed circuit board assembly, a cover, apressure sensor, and a solenoid valve. A pressure sensor support 152′extends towards a printed circuit board assembly (PCBA) 140′ from theinterior of the cover 150′, and retains both the pressure sensor 130′and the PCBA 140′ while withstanding any pressure force pushing on thepressure sensor 130′. The PCBA 140′ has 19 mm of clearance above thefront portion of the PCBA 140′ and 6 mm of clearance above the rearportion of the PCBA 140′ between the PCBA 140′ and the cover 150′. ThePCBA 140′ has 2 mm of clearance beneath it, between the PCBA 140′ andthe manifold 110′, as well as 1.5 mm of clearance around the perimeterof the PCBA 140′. Each solenoid valve 120′ forms a radial seal between a2.8 mm barrel 122′ and a respective interior of the injection-moldedplastic port 111′. Each valve 120′ has a 30 mm long flying lead with aJapan Solderless Terminal (JST) connector 126′, and each pressure sensor120′ is soldered directly to the PCBA 140′. The PCBA 140′ is located andretained by the pressure sensors 130′ as well as a number of tabs andslots 154′ in the cover 150′. There are at least three variations of thesolenoid valve 120′, each built on the same winding bobbin,injection-molded body parts, and stamped steel frame, and varying thesize of the molded orifice, the coil winding, and other internalcomponents. The first variation of the valve 120′ is a two-way, normallyclosed, direct acting solenoid valve with a 1.5 mm orifice. The secondvariation of the valve 120′ is a two-way, normally closed,pressure-balanced direct acting solenoid valve with a 4 min orifice. Thethird variation of the valve 120′ is a three-way, normally closed pilotsolenoid valve with a 0.5 mm orifice. The third variation of the valve120′ can be used to actuate one or more air-piloted valves 172 in asecond manifold stage 170. Each valve 120′ is located in the cavity 115′of the manifold 110′, and has an open frame and coil assembly. Theoperating voltage of the electronics module 140′ is 8 to 16 V. However,the system can include any suitable set of components in any othersuitable configuration.

The system 100 can include any other suitable elements configured tocontrol pressurized airflow, provide mechanical support to internal orexternal components, mount (couple, connect, affix) the system 100 torelated systems (e.g., a vehicle or part of a vehicle), transfer data orelectrical power between elements of the system 100 and externallyconnected systems or components, attach services requiring a source orsink of compressed air or fluid (e.g., fittings), and couple variouselements of the system 100 to one another. Furthermore, as a personskilled in the art will recognize from the previous detailed descriptionand from the figures, modifications and changes can be made to thesystem too without departing from the scope of the system 100.

3. Method of Manufacture

As shown in FIG. 19, an embodiment of a method 200 for manufacturing anelectronically controlled air suspension system includes:injection-molding a manifold; inserting valves into the manifold;positioning pressure sensors within the manifold; and electronicallycoupling an electronics module to the pressure sensors and valves. Themethod 200 can additionally or alternatively include: rotating valvesinto a locked position within the manifold; affixing a cover tocooperatively form an enclosure between the cover and the manifold;filling interior voids of the enclosure with a potting compound; andpost-processing the injection-molded manifold. An electronicallycontrolled air suspension system is preferably a system such as thesystem 100 described above, but can alternatively be any suitablesystem. Injection-molding the manifold can include: splitting the crosssection of the manifold mold along the centerline of the manifold,parallel to the first and second broad faces of the manifold; andmolding the manifold to form webbing between a set of ports defined bythe manifold, to facilitate material flow during injection molding andprovide mechanical strength to the final component. Electronicallycoupling the electronics module to the pressure sensors and valves caninclude: aligning any electrical connectors of the pressure sensors andthe valves in a common direction, coaxially aligning the electricalconnectors of the pressure sensors and the valves and a set ofthrough-holes in the electronics module, and soldering the electricalconnectors of the pressure sensors and the valves to the electronicsmodule at the set of through-holes. In one variation, system assemblycan occur concurrently with component electrical connection. In oneexample, the PCBA can be assembled using top-down assembly, wherein PCBAassembly to the manifold can concurrently connect the pressure sensorsand solenoid valves to the PCBA. However, the system can be otherwiseassembled. Soldering is preferably performed as a single simultaneous orsequential operation, enabled by the electrical connectors all sharing acommon direction and passing through a common plane, but canalternatively be otherwise performed. However, the system can beotherwise manufactured.

The FIGURES illustrate the architecture, functionality and operation ofpossible implementations of systems, methods and computer programproducts according to preferred embodiments, example configurations, andvariations thereof. In this regard, each block in the flowchart or blockdiagrams can represent a module, segment, step, or portion of code,which comprises one or more executable instructions for implementing thespecified logical function(s). It should also be noted that, in somealternative implementations, the functions noted in the block can occurout of the order noted in the FIGURES. For example, two blocks shown insuccession can, in fact, be executed substantially concurrently, or theblocks can sometimes be executed in the reverse order, depending uponthe functionality involved. It will also be noted that each block of theblock diagrams and/or flowchart illustration, and combinations of blocksin the block diagrams and/or flowchart illustration, can be implementedby special purpose hardware-based systems that perform the specifiedfunctions or acts, or combinations of special purpose hardware andcomputer instructions.

As a person skilled in the art will recognize from the previous detaileddescription and from the figures and claims, modifications and changescan be made to the preferred embodiments of the invention withoutdeparting from the scope of this invention defined in the followingclaims.

We claim:
 1. An air suspension control system, comprising: a pluralityof ports comprising a first port, a second port, and a third port, eachof the plurality of ports defining a flow axis extending between a firstand second end of the respective port, wherein the flow axis of thefirst port and the flow axis of the second port are aligned in a commonplane; a channel intersecting the first port and the second port betweenthe first and second ends of the respective port; a cavity intersectingthe second end of each port, and a first pressure port configured toselectively connect to at least one of the first port, the second port,and the channel.